Polymeric composition

ABSTRACT

The invention relates to a polymeric composition, comprising: at least one thermoplastic resin having a glass transition temperature of at least about 220° C.; inorganic particulates having an average particle size in the range up to about 100 nanometers dispersed in the thermoplastic resin, the inorganic particulates having an index of refraction in the range from about 1.4 to about 3; and an effective amount of at least one dispersant to disperse the inorganic particulates in the thermoplastic resin. The polymer composition may be a high temperature thermoplastic suitable for forming, such as by molding, optical articles such as lenses.

This is a division under 35 U.S.C. § 121 of U.S. application Ser. No.11/870,459, filed Oct. 11, 2007. Priority is claimed under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 60/829,158, filed Oct.12, 2006 and to U.S. Provisional Application Ser. No. 60/909,948, filedApr. 4, 2007. These applications are incorporated herein by reference.

TECHNICAL FIELD

This invention relates to polymeric compositions. More particularly,this invention relates to optical polymeric compositions as well asmethods of making such compositions. The invention relates to articles,such as plastic lenses, made from these polymeric compositions.

BACKGROUND

Plastic lenses, glass lenses, and silicone lenses often perform the samefunction in optical systems, such as in cameras, automotive lighting,military night vision equipment, and, particularly, LEDs (Light EmittingDiodes). The main attributes that separate plastic lenses from glasslenses are lower weight, better impact resistance, and lower cost.Glass, however, is more stable at very high temperatures. The differencein cost is due largely to the difference in manufacturing processes thatare required for the two materials and the relative temperaturesrequired to form the materials. Plastic lenses are typically produced atabout 230-390° C. using injection molding at cycle times that are about10 times faster than glass lenses. Glass lenses are typically producedusing grinding and polishing or compression molding at about 625° C.Silicone lenses have very high temperature resistance, yet are moreexpensive to produce than glass. Silicone materials typically cost atleast about 3-5 times as much as glass and plastic materials, andrequire costly molds for either compression molding or liquid injectionprocessing which are performed at relatively slow production rates. Itis easier and less expensive to mold special details into plastic lensesthan glass and silicone lenses.

Industrial lens devices, such as camera lens and LED lens devices, aretypically assembled in solder reflow ovens. Traditionally, lead has beenused as an ingredient in the solder to reduce the melting temperature ofthe solder to just under about 200° C. The problem is that it is oftendesirable to use lead free solder and the temperature required to meltlead free solder may be about 217° C. or higher. This has led to therequirement of solder reflow ovens that operate at higher temperatureswith operating temperatures that typically peak at about 250-285° C. Theincrease in the processing temperatures for solder reflow ovens hascreated the need for injection moldable, optically clear thermoplasticsthat have significantly higher glass transition temperatures (Tg). Thisinvention provides a solution to this problem.

SUMMARY

This invention relates to a polymer composition, comprising: at leastone thermoplastic resin having a glass transition temperature of atleast about 220° C.; inorganic particulates having an average particlesize in the range up to about 100 nanometers (nm) dispersed in thethermoplastic resin, the inorganic particulates having an index ofrefraction in the range from about 1.4 to about 3; and an effectiveamount of at least one dispersant to disperse the inorganic particulatesin the thermoplastic resin. In one embodiment, the composition furthercomprises at least one bluing agent. In one embodiment, the compositionfurther comprises at least one ultraviolet light absorber. In oneembodiment, the composition further comprises at least one antioxidant.In one embodiment, the composition further comprises one or more heatstabilizers, antistatic agents, pigments, dyes, optical brightners,flame retardants, or a mixture of two or more thereof. In oneembodiment, the composition further comprises one or more meltprocessable glass reinforcing resins or materials.

In one embodiment, the invention relates to an additive composition madeby combining: at least one dispersant; inorganic particulates having anaverage particle size in the range up to about 100 nanometers, theinorganic particulates having an index of refraction in the range fromabout 1.4 to about 3; at least one dye concentrate comprising (i) atleast one dispersant, (ii) at least one bluing agent, and (iii)inorganic particulates having an average particle size in the range upto about 100 nanometers, the inorganic particulates having an index ofrefraction in the range from about 1.4 to about 3. The additivecomposition may further comprise one or more antioxidants, UV lightstabilizers, heat stabilizers, antistatic agents, pigments, dyes,optical brighteners, flame retardants, or a mixture of two or more.

In one embodiment, the invention relates to a polymer compositioncomprising at least one thermoplastic resin having a glass transitiontemperature of at least about 220° C. and the foregoing additivecomposition.

In one embodiment, the invention relates to a molded article comprisingthe foregoing polymer composition. The molded article may comprise alens.

In one embodiment, the invention relates to a method of making a polymercomposition, comprising: heating pellets of a thermoplastic resin at atemperature of at least about 70° C., the thermoplastic resin having aglass transition temperature of at least about 220° C.; and coating thepellets with the foregoing additive composition.

In one embodiment, the invention relates to a process of forming anarticle, comprising: feeding pellets comprising a thermoplastic resinhaving a glass transition temperature of at least about 220° C. coatedwith the foregoing additive composition, to an injection moldingapparatus and molding the article in the apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 includes graphs of the theoretical transmission and actualtransmission of as-molded, high temperature optical thermoplasticcompositions in accordance with an embodiment of the invention asdescribed in Example 1.

FIG. 2 is a DSC-TGA graph of a high temperature, optical thermoplasticcomposition in accordance with an embodiment of the invention asdescribed in Example 4.

FIG. 3 is a DMTA graph of a high temperature, optical thermoplasticcomposition in accordance with an embodiment of the invention asdescribed in Example 3.

FIGS. 4-6 are photographs showing the stress characteristics ofun-annealed and annealed high temperature, optical thermoplasticcompositions in accordance with an embodiment of the invention asdescribed in Example 5.

DETAILED DESCRIPTION

All ranges and ratio limits disclosed in the specification may becombined. It is to be understood that unless specifically statedotherwise, references to “a,” “an,” and/or “the” may include one or morethan one and that reference to an item in the singular may also includethe item in the plural.

The polymer composition may comprise at least one thermoplastic resinhaving a glass transition temperature (Tg) of at least about 220° C.,and in one embodiment at least about 225° C., and in one embodiment atleast about 230° C., and in one embodiment at least about 235° C. Thethermoplastic resin may comprise one or more of polycarbonate,polysulfone, polyolefin (e.g., polypropylene), polystyrene, polyalkyleneterephthates (e.g., polyethylene terephthalates (PET)), or a mixture oftwo or more thereof. Copolymers of two or more of the foregoing may beused. The term “copolymer” is used herein to refer to a polymercomposition containing two or more different repeating units. The termcopolymer is meant to encompass copolymers, terpolymers, and the like.

The polycarbonates may comprise one or more homopolycarbonates,copolycarbonates, thermoplastic polyester-carbonates, or a mixture oftwo or more thereof. The polycarbonate may comprise at least onebisphenol of the general formula HO—Z—OH, wherein Z is a divalentorganic group having from about 6 to about 30 carbon atoms and one ormore aromatic groups. The bisphenol may comprise one or moredihydroxydiphenyls, bis(hydroxyphenyl)alkanes, indanebisphenols,bis(hydroxy-phenyl)ethers, bis(hydroxyphenyl)sulfones,bis(hydroxyphenyl)ketones, α,α′-bis(hydroxyphenyl)-diisopropylbenzenes,and the like. Examples of bisphenols that may be used may include para,para isopropylidene diphenol (bisphenol A), tetraalkylbisphenol A,4,4-(meta-phenylenediisopropyl)-diphenol (bisphenol M),4,4-(para-phenylenediisopropyl)-diphenol,1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (bisphenol TMC), ora mixture of two or more thereof. The polycarbonate may comprise ahomopolycarbonate based on monomers of bisphenol A. The polycarbonatemay comprise a copolycarbonate based on monomers of bisphenol A andbisphenol TMC. The bisphenol may be reacted with one or more carbonicacid compounds, for example, phosgene, diphenyl carbonate or dimethylcarbonate.

The polycarbonate may comprise a mixture of two or more polycarbonates.For example, the polycarbonate may comprise a mixture of a polycarbonatemade from bisphenol A and a polycarbonate made from bisphenol TMC.

Polyester-carbonates may be obtained by reaction of one or more of theforegoing bisphenols with one or more aromatic dicarboxylic acids andoptionally one or more carbonic acid equivalents. The aromaticdicarboxylic acids may include, for example, orthophthalic acid,terephthalic acid, isophthalic acid, 3,3′- or 4,4′-diphenyldicarboxylicacid, one or more benzophenonedicarboxylic acids, or a mixture of two ormore thereof. Up to about 80 mol %, and in one embodiment from about 20to about 50 mol %, of the carbonate groups in the polycarbonate may bereplaced by aromatic dicarboxylic acid ester groups.

Inert organic solvents may be used in the reaction to form thepolycarbonate. These may include methylene chloride, dichloroethane,chloropropane, carbon tetrachloride, chloroform, chlorobenzene,chlorotoluene, or a mixture of two or more thereof.

The reaction to form the polycarbonate may be accelerated by catalysts,such as tertiary amines, N-alkylpiperidines, onium salts, or a mixtureof two or more thereof. Tributylamine, triethylamine and/orN-ethylpiperidine may be used.

The polycarbonate may be branched deliberately and in a controlledmanner by the use of small amounts of branching agents. Suitablebranching agents may include, for example, phloroglucinol;4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-hept-2-ene;4,6-dimethyl-2,4,6-tri-(4-hydroxyphenyl)-heptane;1,3,5-tri-(4-hydroxyphenyl)-benzene; 1,1,1-tri-(4-hydroxyphenyl)-ethane;tri-(4-hydroxyphenyl)-phenylmethane;2,2-bis-[4,4-bis-4-hydroxyphenyl)-cyclohexyl]propane;2,4-bis-(4-hydroxyphenyl-isopropyl)-phenol;2,6-bis-(2-hydroxy-5′-methyl-benzyl)-4-methylphenol;2-(4-hydroxyphenyl)-2-(2,4-dihydroxyphenyl)-propane;hexa-(4-(4-hydroxyphenyl-isopropyl)-phenyl)-orthoterephthalic acidester, tetra-(4-hydroxyphenyl)-methane;tetra-(4-(4-hydroxyphenyl-isopropyl)-phenoxy)-methane;α,α′,α″-tris-hydroxyphenyl-1,3,5-triisopropylbenzene;2,4-dihydroxybenzoic acid; trimesic acid; cyanuric chloride;3,3-bis-(3-methyl-4-hydroxyphenyl)-2-oxo-2,3-dihydroindole;1,4-bis-(4′,4″-dihydroxytriphenyl)-methyl)benzene;1,1,1-tri-(4-hydroxyphenyl)-ethane and/or3,3-bis-(3-methyl-4-hydroxyphenyl)-2-oxo-2,3-dihydroindole.

One or more chain stoppers may be used in the reaction to form thepolycarbonate. The chain stopper may comprise one or more phenols, suchas phenol, alkylphenols, such as cresol or 4-tert-butylphenol,chlorophenol, bromophenol, cumylphenol, or mixtures of two or morethereof.

The polycarbonate may be referred to as being an injection moldable,optically clear thermoplastic with a high glass transition temperature(Tg). The polycarbonate may have a Tg of at least about 200° C., and inone embodiment from about 200 to about 235° C., or higher. The Tg may beat least about 220° C., and in one embodiment at least about 227° C.,and in one embodiment at least about 235° C. The Tg may be in the rangefrom about 220 to about 290° C., and in one embodiment from about 220°C. to about 260° C., and in one embodiment from about 235° C. to about290° C., and in one embodiment from about 235° C. to about 260° C.

The polycarbonate may have a weight average molecular weight (M_(w)) inthe range from about 20,000 to about 40,000, and in one embodiment inthe range from about 26,000 to about 36,000, and in one embodiment inthe range from about 28,000 to about 35,000, and in one embodiment fromabout 31,000 to about 35,000, and in one embodiment about 33,000, asdetermined by measuring the relative solution viscosity of thepolycarbonate in methylene chloride or in a mixture of equal amounts byweight of phenol/-o-dichlorobenzene, calibrated by light scattering.

The polycarbonate may be produced by the synthesis of bisphenol A withbisphenol TMC. Alternatively, a mixture of a polycarbonate made frombisphenol A and a polycarbonate made from bisphenol TMC may be used. Thepolycarbonate may have a Vicat Softening Temperature in the range offrom about 225° C. to about 235° C., and a Tg greater than about 227° C.Polycarbonates available from Bayer under the trade designation APEC® TP0277 may be used.

The concentration of the thermoplastic resin in the polymer compositionmay be at least about 15% by weight, and in one embodiment at leastabout 50% by weight, and in one embodiment at least about 75% by weight,and in one embodiment at least about 90% by weight, and in oneembodiment at least about 95% by weight, and in one embodiment at leastabout 97.3% by weight, and in one embodiment in the range from about 15to about 99.8% by weight based on the total weight of the polymercomposition, and in one embodiment from about 50 to about 99.8% byweight, and in one embodiment from about 75 to about 99.8% by weight,and in one embodiment from about 90 to about 99.8% by weight, and in oneembodiment from about 95 to about 99.8% by weight, and in one embodimentfrom about 97.3 to about 99.75% by weight.

The inorganic particulates may be referred to as nanomaterials, forexample, transparent nanomaterials and/or as high temperature resistantnanomaterials. These particulates may be used to enhance the dispersionof visible light in molded articles made from the polymer composition.As such, these particulates may contribute to providing optically clearmolded articles made from the polymer composition. These particulatesmay also serve as a dispersant aid, suspension aid, and/or flow aid forthe thermoplastic resin. The inorganic particulates may comprisealuminum oxide, silicon dioxide, silicon, cerium oxide, titaniumdioxide, zirconium oxide, or a mixture of two or more thereof. Theaverage particle size of the inorganic particulates may be in the rangeup to about 100 nm, and in one embodiment in the range from about 1 toabout 100 nm, and in one embodiment in the range from about 1 to about75 nm, and in one embodiment in the range from about 1 to about 50 nm,and in one embodiment in the range from about 3 to about 50 nm, and inone embodiment from about 5 to about 50 nm, and in one embodiment fromabout 5 to about 40 nm, and in one embodiment from about 5 to about 30nm, and in one embodiment from about 5 to about 20 nm, and in oneembodiment from about 5 to about 15 nm. The inorganic particulates mayhave a refractive index in the range from about 1.4 to about 3, and inone embodiment in the range from about 1.4 to about 2.5, and in oneembodiment in the range from about 1.4 to about 2, and in one embodimentin the range from about 1.4 to about 1.8, and in one embodiment in therange from about 1.5 to about 1.6. The refractive index may be in therange from about 1.42 to about 3, and in one embodiment in the rangefrom about 1.42 to about 2.5, and in one embodiment in the range fromabout 1.42 to about 2, and in one embodiment in the range from about1.52 to about 1.58, and in one embodiment in the range from about 1.54to about 1.58, and in one embodiment about 1.56. The inorganicparticulates may have a relatively high zeta potential. The zetapotential may be at least about +30 mV or more negative than −30 mV, andin one embodiment at least about +35 mV or more negative than −35 mV.The inorganic particulates may be thermally stable at temperatures up toabout 350° C., in one embodiment up to about 400° C., and in oneembodiment up to about 600° C., and in one embodiment up to about 800°C., and in one embodiment up to about 1000° C. or higher. Examples ofinorganic particulates that may be used may include Aluminum Oxide Cand/or Aeroxide Alu US available from Degussa Corporation.

The inorganic particulates may be silane treated to enhance dispersionof the inorganic particulates into the polymer and to optionally couplethe inorganic particulates to the polymer resin system. Examples ofsilanes that may be used may include Dynasylan OCTEO(octyltriethoxsilane), Dynasylan DAMO(N-2-aminoethyl-3-aminopropyltrimethoxysilane) and Dynasylan 9165(phenyltrimethoxysilane). Blends of Dynasylan DAMO and Dynasylan 9165may be used. These may be thermally stable at temperatures up to about370° C. or higher and are available from Degussa Corporation.

The inorganic particulates may be surface treated with one or moretitanates, one or more zirconates, or a mixture thereof. The titanatesand zirconates may comprise one or more organometallic complexes oftitanium or zirconium complexed by one or more organic compoundscontaining functional groups attached to a hydrocarbon linkage. Theorganic compounds may contain one or more, and in one embodiment, two ormore functional groups. The functional groups may comprise one or moreof ═O, ═S, —OR, —SR, —NR₂, —NO₂, ═NOR, ═NSR and/or —N═NR, wherein R ishydrogen or a hydrocarbon group (e.g., alkyl or alkenyl) of 1 to about10 carbon atoms. The titanates and zirconates may include alkoxytitanates and coordinate zirconates. These may include the alkoxytitanates available under the tradenames LICA 12 or KR-PRO, from KenrichPetrochemicals, Inc., Bayonne, N.J., and the coordinate zirconatesavailable under the tradenames KZ 55 or KR 55, from Kenrich.

The concentration of the inorganic particulates in the polymercomposition may be in the range up to about 30% by weight, and in oneembodiment in the range from about 0.0001 to about 30% by weight, and inone embodiment in the range from about 0.0001 to about 25% by weight,and in one embodiment from about 0.0001 to about 20% by weight, and inone embodiment from about 0.0001 to about 10% by weight, and in oneembodiment in the range from about 0.001 to about 5% by weight, and inone embodiment from about 0.01 to about 2% by weight, and in oneembodiment from about 0.01 to about 1% by weight, based on the totalweight of the polymer composition. The concentration of the inorganicparticulates in the additive composition that may be used in making thepolymer composition may be in the range from about 0.5 to about 20% byweight based on the total weight of the additive composition, and in oneembodiment from about 1 to about 10% by weight.

The dispersant may comprise any material that enhances the dispersion ofthe inorganic particulates in the thermoplastic resin. The dispersantmay comprise one or more fatty acids, fatty esters, fatty amides, fattyalcohols, or a mixture of two or more thereof. The fatty acids maycomprise one or more saturated and/or unsaturated monocarboxylic acidsof about 10 to about 36 carbon atoms, and in one embodiment from about14 to about 26 carbon atoms, and in one embodiment about 12 to about 22carbon atoms. The saturated monocarboxylic acids may comprise one ormore of myristic acid, palmitic acid, stearic acid, arachidic acid,behenic acid, and/or hexatrieisocontanoic acid. The unsaturatedmonocarboxylic acids may comprise one or more of palmitoleic acid, oleicacid, linoleic acid, linolenic acid and/or cetoleic acid. Mixtures oftwo or more of the foregoing acids may be used.

The fatty esters may comprise one or more esters of one or more of theforegoing carboxylic acids and one or more alcohols. The alcohol maycomprise one or more monohydric alcohols and/or one or more polyhydricalcohols. The monohydric alcohols may include alcohols of 1 to about 5carbon atoms such as methyl alcohol, ethyl alcohol, propyl alcohol,butyl alcohol, pentyl alcohol, or a mixture of two or more thereof. Thepolyhydric alcohols may include glycerol, erythritol, pentaerythritol,dipentaerythritol, gluconic acid, glyceraldehyde, glucose, arabinose,1,7-heptanediol, 2-4-heptanediol, 1,2,3-hexanetriol, 1,2,4-hexanetriol,1,2,5-hexanetriol, 2,3,4-hexanetriol, 1,2,3-butanetriol,1,2,4-butanetriol, quinic acid,2,2,6,6-tetrakis-(hydroxymethyl)cyclohexanol, 1,10-decanediol,digitalose, or a mixture of two or more thereof. Examples of the estersthat may be used may include methylstearate, butylstearate, ethyloleate,butyllinoleate, glycerol monolaurate, glycerol monooleate, glycerolmonoricinoleate, glycerol monostearate, glycerol distearate, glyceroltristearate, pentaerythritol tetrastearate, or a mixture of two or morethereof. The fatty ester may comprise one or more saturated fattyesters, one or more unsaturated fatty esters, or a mixture thereof. Thefatty ester may comprise a solid material at room temperature, forexample, a dry powder.

The fatty amides may comprise one or more amides of one or more of theforegoing carboxylic acids and ammonia and/or at least one amine. Theamine may comprise one or more monoamines, one or more polyamines, oneor more hydroxyamines and/or one or more alkoxylated amines. Themonoamines may include methylamine, ethylamine, diethylamine,n-butylamine, di-n-butylamine, allylamine, isobutylamine, cocoamine,stearylamine, laurylamine, methyllaurylamine, oleylamine,N-methyl-octylamine, dodecylamine, octadecylamine, or a mixture of twoor more thereof. The polyamies may include the alkylene polyamines suchas ethylene diamine, diethylene, triamine, triethylene tetramine,tetraethylene pentamine, pentaethylene hexamine, propylene diamine,trimethylene diamine, hexamethylene diamine, decamethylene diamine,octamethylene diamene, di(heptamethylene)triamine, tripropylenetetramine, di(trimethylene)triamine, N-(2-aminoethyl) peperazine, or amixture of two or more thereof. The hydroxyamines may comprise one ormore primary alkanol amines, one or more secondary alkanol amines, or amixture thereof. The hydroxyamines may be referred to as aminoalcohols.Examples may include 2-amino-1-butanol, 2-amino-2-methyl-1-propanol,p-(beta-hydroxyethyl)-aniline, 2-amino-1-propanol, 3-amino-1-propanol,2-amino-2-methyl-1,3-propanediol, 2-amino-2-ethyl-1,3-propanediol,N-(beta-hydroxypropyl)-N′-(beta-aminoethyl)-piperazine,tris(hydroxymethyl) amino methane, 2-amino-1-butanol, ethanolamine,beta-(beta-hydroxyethoxy)-ethyl amine, glucamine, glusoamine,N-3-(aminopropyl)-4-(2-hydroxyethyl)-piperadine,2-amino-6-methyl-6-heptanol, 5-amino-1-pentanol,N-(beta-hydroxyethyl)-1,3-diamino propane, 1,3-diamino-2-hydroxypropane,N-(beta-hydroxy ethoxyethyl)-ethylenediamine, trismethylolaminomethane,or a mixture of two or more thereof. The alkoxylated amines may includethe alkoxylated alkylene polyamines such asN,N(diethanol)ethylenediamine, N-(2-hydroxyethyl)ethylene diamine,N,N-bis(2-hydroxyethyl)-ethylene-diamine, 1-(2-hydroxyethyl) piperazine,mono(hydroxypropyl)-substituted diethylene triamine,di(hydroxypropyl)-substituted tetraethylene pentamine,N-(3-hydroxybutyl)-tetramethylene diamine, or a mixture of two or morethereof.

The fatty amide may comprise stearamide, oleamide, linoleamide,linolenamide, or a mixture of two or more thereof. The fatty amide maycomprise one or more alkylenebisfattyamides, such asethylenebistearamide, ethylenebisoleamide, ethylenebislinoleamide, or amixture of two or more thereof.

The fatty alcohols may comprise one or more saturated fatty alcohols,one or more unsaturated fatty alcohols, or a mixture thereof. Thesaturated fatty alcohols may include octyl alcohol, decylalcohol, laurylalcohol, myristyl alcohol, cetyl alcohol, stearyl alcohol, or a mixtureof two or more thereof. The unsaturated fatty alcohols may include oleylalcohol, linoleyl alcohol, linolenyl alcohol, or a mixture of two ormore thereof.

The dispersant may comprise one or more polyalkylene glycols,polyoxyalkylene glycols, or a mixture thereof. Examples may includediethylene glycol, triethylene glycol, tetraethylene glycol, dipropyleneglycol, tripropylene glycol, dibutylene glycol, tributylene glycol, aswell as other alkylene glycols and polyoxyalkylene glycols in which thealkylene groups contain from 2 to about 8 carbon atoms. Mixtures of twoor more of the foregoing may be used.

The dispersant may comprise one or more titanates, one or morezirconates, or a mixture thereof. The titanates and zirconates maycomprise one or more organometallic complexes of titanium or zirconiumcomplexed by one or more organic compounds containing functional groupsattached to a hydrocarbon linkage. The organic compounds may contain oneor more, and in one embodiment, two or more functional groups. Thefunctional groups may comprise one or more of ═O, ═S, —OR, —SR, —NR₂,—NO₂, ═NOR, ═NSR and/or —N═NR, wherein R is hydrogen or a hydrocarbongroup (e.g., alkyl or alkenyl of 1 to about 10 carbon atoms). Thetitanates and zirconates may include alkoxy titanates and coordinatezirconates. These may include the alkoxy titanates available under thetradenames LICA 12 or KR-PRO, from Kenrich Petrochemicals, Inc.,Bayonne, N.J., and the coordinate zirconates available under thetradenames KZ 55 or KR 55, from Kenrich. These may be provided in liquidor powder form. The powder may be formed by sorbing liquid titanate orzirconate on inorganic particulates, such as fumed silica or aluminumoxide. For example, a titanate or zirconate powder may be prepared bydrip blending two parts titanate or zirconate liquid on one partaluminum oxide particulates. The titanates may be thermally stable to350° C. and the zirconates may be thermally stable to 400° C. Thezirconates may be used with a phenol antioxidant, thermal stabilizer.

The dispersant may comprise one or more hydrocarbon dispersants,including natural or synthetic paraffins, polyethylene waxes, ormixtures of two or more thereof. The dispersant may comprise one or morefluorocarbons. The dispersant may comprise one or more silicone releaseagents such as one or more silicone oils.

The dispersant may comprise one or more surfactants. These may includeionic and/or non-ionic surfactants. The ionic surfactants may becationic and/or anionic compounds. These compounds may have ahydrophilic lipophilic balance (HLB) up to about 20, and in oneembodiment in the range from about 1 to about 20. The surfactants thatmay be used may include those disclosed in McCutcheon's Emulsifiers andDetergents, 1993, North American & International Edition. Examples mayinclude alkanolamides, alkylarylsulphonates, amine oxides,poly(oxyalkylene) compounds, including block copolymers comprisingalkylene oxide repeat units, carboxylated alcohol ethoxylates,ethoxylated alcohols, ethoxylated alkyl phenols, ethoxylated amines andamides, ethoxylated fatty acids, ethoxylated fatty esters and oils,fatty esters, glycerol esters, glycol esters, imidazoline derivatives,lecithin and derivatives, lignin and derivatives, monoglycerides andderivatives, olefin sulphonates, phosphate esters and derivatives,propoxylated and ethoxylated fatty acids or alcohols or alkyl phenols,sorbitan derivatives, sucrose esters and derivatives, sulphates oralcohols or ethoxylated alcohols or fatty esters, polyisobutylenesuccinicimide and derivatives, sulphonates of dodecyl and tridecylbenzenes or condensed naphthalenes or petroleum, sulphosuccinates andderivatives, tridecyl and dodecyl benzene sulphonic acids, and mixturesof two or more thereof.

The dispersant may also function as an internal lubricant, mold releaseand/or processing aid. The dispersant may function as a dispersant forother additive materials in addition to the inorganic particulates. Thedispersant may be hydrophobic. The dispersant may have a melttemperature in the range from about 50 to about 200° C., and in oneembodiment from about 60 to about 170° C., and in one embodiment about65° C. The dispersant may be thermally stable at a temperature up toabout 350° C., and in one embodiment up to about 400° C. or higher.

The dispersant may include INT-40DHT, which is a product that may beavailable from Axel Plastics Research Laboratories, Inc., Woodsie, N.Y.INT-40DHT. The product may be thermally stable up to about 400° C.INT-40DHT may be identified as a mixture of saturated and unsaturatedfatty esters with modified organic derivatives. INT-40 DHT may beidentified as a mixture of one or more fatty acids, fatty esters andglycerides.

The dispersant may be INT-33UDY or INT-33UDS from Axel Plastics. Thesemay be identified as a mixture of one or more fatty amides and one ormore surfactants. INT 33UDY may be thermally stable up to about 350° C.,and INT-33UDS may be stable up to about 400° C.

The bluing agent may be used to enhance the color quality of moldedarticles made from the polymer composition. The bluing agent may be usedto offset yellow color formation in the polymer composition so as tooptically clarify the polymer composition. The bluing agent may compriseat least one blue dye, or a mixture of at least one blue dye and atleast one violet dye. The blue dye may be Amplast Blue R3 or AmplastBlue HB, which may be available from ColorChem International Corp. andare identified as being insoluble blue dyes in the form of a dry powderthat melts at about 170° C. and is thermally stable at temperatures upto about 400° C. The violet dye may be Amplast Violet BV or AmplastViolet PK which may be available from ColorChem International Corp. andare identified as being unsoluble violet dyes in the form of dry powdersthat melt at about 170° C. and are thermally stable at temperatures upto about 400° C. The concentration of the bluing agent in the polymercomposition may be in the range from about 0.05 to about 4 parts permillion based on the weight of the polymer composition. Theconcentration of the bluing agent in the additive composition that maybe used in making the polymer composition may be in the range from about0.0005 to about 0.008% by weight based on the total weight of theadditive composition, and in one embodiment from about 0.001 to about0.004% by weight.

The bluing agent may be provided in the form of a dye concentrate whichmay comprise (i) at least one dispersant; (ii) at least one dye, and(iii) inorganic particulates having an average particle size in therange up to about 100 nm and an index of refraction in the range fromabout 1.4 to about 2.5. The dispersant, dye and inorganic particulatesmay be the same as described above. The specific dispersant and and/orinorganic particulates in the dye concentrate may be the same, or eitheror both may be different than the specific dispersant and inorganicparticulates supplied to the polymer composition separately from the dyeconcentrate. As indicated above, the dye may be a blue dye, or a mixtureof blue and violet dyes. The concentration of dispersant in the dyeconcentrate may be in the range from about 98.5 to about 99.8% byweight, and in one embodiment from about 99.0 to about 99.6% by weight.The concentration of the dye in the dye concentrate may be in the rangefrom about 0.05 to about 0.8% by weight, and in one embodiment fromabout 0.2 to about 0.6% by weight. The concentration of the inorganicparticles in the dye concentrate may be in the range from about 0.05 toabout 1% by weight, and in one embodiment from about 0.1 to about 0.5%by weight. The dye concentrate may be in the form of a dry powder whichmay be thermally stable up to at least about 350° C., and in oneembodiment up to at least about 400° C. The concentration of the dyeconcentrate in the polymer composition may be in the range from about0.001 to about 0.01% by weight based on the total weight of the polymercomposition, and in one embodiment from about 0.004 to about 0.008% byweight. The concentration of the dye concentrate in the additivecomposition that may be used in making the polymer composition may be inthe range from about 0.5 to about 6% by weight based on the total weightof the additive composition, and in one embodiment from about 1 to about4% by weight.

The dye concentrate may be made by mixing and optionally grinding thematerials selected for use in the dye concentrate. An example of a dyeconcentrate which may be a homogenous, free-flowing, dry powder is shownin Table 1.

TABLE 1 % by Weight of Total Dye Con- Material: centrate Formula: (1)mixture of saturated and unsaturated fatty esters;  98.4-99.7 or (2)mixture of organic fatty amides with surfactants; or a mixture of (1)and (2) High temperature stable blue dye/dry powder 0.05-0.3 Hightemperature stable violet dye/dry powder 0.05-0.3 Inorganic particulatesolids with average particle 0.05-1.0 size <100 nm.

In one embodiment, the dye concentrate may have a formula set forth inTable 2.

TABLE 2 % by Weight of Total Dye Con- Material: centrate Formula: (1)Mixture of saturated and unsaturated fatty esters; 99.4 or (2) mixtureof organic fatty amides with surfactants; or a mixture of both (1) and(2) High temperature stable blue dye/dry powder 0.2 High temperaturestable violet dye/dry powder 0.2 Inorganic particulates with averageparticle 0.2 size <100 nm

The dye concentrate may be made in the form of a homogenous paste. Anexample of a homogenous paste concentrate is shown in Table 3.

TABLE 3 % by Weight of Total Dye Con- Material: centrate Formula:Titanate or zirconate liquid 98.4-99.7 High temperature stable bluedye/dry powder 0.05-0.3  High temperature stable violet dye/dry powder0.05-0.3  Inorganic particulate solids with average particle 0.1-1.0size <100 nm.

In one embodiment, the dye concentrate may have the formula set forth inTable 4.

TABLE 4 % by Weight of Total Dye Con- Material: centrate Formula:Titanate or zirconate liquid 99.4 High temperature stable blue dye/drypowder 0.2 High temperature stable violet dye/dry powder 0.2 Inorganicparticulates with average particle 0.2 size <100 nm

The ultraviolet (UV) light absorber may be used to provide hydrolyticand/or thermal stability to the polymer composition and/or long termhydrolytic, photolytic, and/or thermal stability to articles molded fromthe polymer composition. The UV light absorber may be referred to as aUV light stabilizer. The UV light absorber may be may be thermallystable up to a temperature of about 350° C., and in one embodiment up toabout 400° C. or higher. In one embodiment the UV absorber may bethermally stable up to at least about 400° C. when combined with thefatty ester and inorganic particulates described above. Materialssuitable for use as the UV light absorber may include tetraethyl 2,2′(1,4-phenylenedimethylidyne) bis malonate. A suitable material may beHostavin® B-CAP which is available from Clariant Corporation, Charlotte,N.C. The UV absorber may comprise one or more substituted triazines,such as2,4-bis(2,4-dimethylphenyl)-6-(2-hydroxy-4-n-octyloxyphenyl)-1,3,5-triazine(CYA-SORB® UV-1164) or2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-(hexyl)oxyphenol (Tinuvin® 1577).The UV absorber may comprise2,2-methylenebis-(4-(1,1,3,3-tetramethylbutyl)-6-(2H-benzotriazol-2-yl)phenol).The UV absorber may comprise one or more benzophenone compounds such as2,4-dihydroxybenzophenone, 2-hydroxy-4-methoxybenzophenone,2-hydroxy-4-octoxybenzophenone, 2-hydroxy-4-benzyloxybenzophenone,2-hydroxy-4-methoxy-5-sulfoxybenzophenone,2-hydroxy-4-methoxy-5-sulfoxytrihydride benzophenone,2,2′-dihydroxy-4-methoxybenzophenone,2,2′,4,4′-tetrahydroxybenzophenone,2,2′-dihydroxy-4,4′-dimethoxybenzophenone,2,2′-dihydroxy-4,4′-dimethoxy-5-sodium sulfoxybenzophenone,bis(5-benzoyl-4-hydroxy-2-methoxyphenyl)methane,2-hydroxy-4-n-dodecyloxybenzophenone and/or2-hydroxy-4-methoxy-2′-carboxybenzophenone. The UV absorber may compriseone or more benzotriazole compounds such as2-(2-hydroxy-5-methylphenyl)benzotriazole,2-(2-hydroxy-5-tert-octylphenyl)benzotriazole,2-(2-hydroxy-3,5-dicumylphenyl)phenylbenzotriazole,2-(2-hydroxy-3-tert-butyl-5-methylphenyl)-5-chlorobenzotriazole,2,2′-methylenebis[4-(1,1,3,3-tetramethylbutyl)-6-(2N-benzotriazol-2-yl)phenol],2-(2-hydroxy-3,5-di-tert-butylphenyl)benzotriazole,2-(2-hydroxy-3,5-di-tert-butylphenyl)-5-chlorobenzotriazole,2-(2-hydroxy-3,5-di-tert-amylphenyl)benzotriazole,2-(2-hydroxy-5-tert-octylphenyl)benzotriazole,2-(2-hydroxy-5-tert-butylphenyl)benzotriazole,2-(2-hydroxy-4-octoxyphenyl)benzotriazole,2,2′-methylenebis(4-cumyl-6-benzotriazolephenyl),2,2′-p-phenylenebis(1,3-benzooxazin-4-one) and/or2-[2-hydroxy-3-(3,4,5,6-tetrahydrophthalimidomethyl)-5-methylphenyl]benzotriazole.The concentration of the UV light absorber in the polymer compositionmay be in the range from about 0.01 to about 0.2% by weight based on thetotal weight of the polymer composition, and in one embodiment fromabout 0.02 to about 0.1% by weight. The concentration of the UV lightabsorber in the additive composition that may be used in making thepolymer composition may be in the range from about 3 to about 20% byweight based on the total weight of the additive composition, and in oneembodiment from about 4 to about 10% by weight.

The antioxidant may comprise a high molecular weight, low volatilityprimary antioxidant and/or a high molecular weight, low volatilitysecondary antioxidant. The antioxidant may be suitable for substantiallyreducing or eliminating yellowing of the thermoplastic resin duringprocessing. The primary antioxidant may be thermally stable up to about350° C., and in one embodiment up to about 400° C. or greater. In oneembodiment the primary antioxidant may be thermally stable up to about400° C. or greater when combined with the fatty ester and inorganicparticulates described above. The primary antioxidant may have amolecular weight in the range from about 550 to about 750.

The primary antioxidant may comprise one or more hindered phenols. Thesemay include one or more of1,3,5-tris(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl)s-triazine-2,4,6-(1H,3H,5H)-trione; 4,4′-isopropylidene-diphenol;butylated hydroxyanisole;1,3,5-trimethyl-2,4,6-tris(3,5-di-di-tert-butyl-4-hydroxybenzyl)benzene;4,4′-methylene-bis(2,6-di-tert-butylphenol);1,1,3-tris(2-methyl-4-hydroxy-5-tert-butylphenyl) butane;2,6-di-tert-butyl-4-ethylphenol;bis-[3,3-bis-(4′-hydroxy-3′-tert-butyl-phenyl-butanoic acid]-glycolester; 1,1,3-tris(2-methyl-4-hydroxy-5-tert-butyl-phenyl)butane;4,4′-thio-bis(6-tert-butyl-m-cresol);4,4-thio-bis(2-tert-butyl-m-cresol);4,4′-butylidene-bis(2-tert-butyl-m-cresol); 2,6-di-tert-butyl-p-cresol;2,6-di-tert-butyl-4-sec-butylphenol;2,2′-methylene-bis(4-ethyl-6-tert-butylphenol);1,3,5-(4-tert-butyl-3-hydroxy-2,6-dimethylbenzyl)-1,3,5-triazine-2,4,6-(1H,3H,5G)-trione;2,2′-methylene-bis(4-methyl-6-tert-butylphenol);1,6-hexamethylene-bis(3,5-di-tert-butyl-4-hydroxyhydrocinnamate);tetrakis{methylene-3-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate}methane;octadecyl-3-(3′5-di-tert-butyl-4-hydroxyphenyl)propionate;1,3,5-tris(3,5-di-tert-butyl-4-hydroxybenzyl)isocyanurate;3,5-di-tert-butyl-4-hydroxyhydrocinnamic acid trimester, or mixtures oftwo or more thereof. A hindered phenol that may be used may be1,3,5-tris(2-hydroxyethyl)-s-triazine-2,4,6-(1H,3H,5H)trione which maybe available as Cyanox® 1790 from Cytec Industries, West Paterson, N.J.

The concentration of the primary antioxidant in the polymer compositionmay be in the range up to about 1% by weight, and in one embodiment fromabout 0.01 to about 1% by weight based on the total weight of thepolymer composition, and in one embodiment from about 0.03 to about0.07% by weight. The concentration of the primary antioxidant in theadditive composition that may be used in making the polymer compositionmay be in the range up to about 10% by weight, and in one embodimentfrom about 1 to about 10% by weight based on the total weight of theadditive composition, and in one embodiment from about 3 to about 7% byweight.

The secondary antioxidant may be used to reduce yellowing of the polymercomposition during high temperature processing. The secondaryantioxidant may also provide hydrolytic and/or thermal stability to thepolymer composition during processing. The secondary antioxidant mayprovide long term hydrolytic, photolytic, and/or thermal stability tomolded articles formed from the polymer composition. The secondaryantioxidant may be thermally stable up to a temperature of at leastabout 350° C., and in one embodiment up to at least about 400° C. In oneembodiment, the secondary antioxidant may be thermally stable up to atleast about 400° C. when combined with at least one fatty ester andinorganic particulates as discussed above.

The secondary antioxidant may comprise at least one phosphite. Thesecondary antioxidant may comprise one or more ofbis(aralkylphenyl)pentaerythritol diphosphite,bis(2,4-dicumylphenyl)pentaerythritol diphosphite,distearylpentaerythritol diphosphite, dioctylpentaerythritoldiphosphite, diphenylpentaerythritol diphosphite,bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite,bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite,dicyclohexylpentaerythritol diphosphite, or a mixture of two or morethereof.

A useful secondary antioxidant may bebis(2,4-dicumylphenyl)pentaerythritol diphosphite available asDoverphos® S-9228PC from Dover Chemical Corporation, Dover, Ohio.Doverphos S-9228PC may be advantageous for use with polycarbonates dueto the fact it has a maximum sodium content of about 200 parts permillion, which may be effective for enhancing optical clarity and/oravoiding leaching of sodium from the molded article. This material mayhave a melting point of about 220° C. or higher. This material exhibitsgood hydrolytic stability, and may be thermally stable at temperaturesup to about 400° C.

The concentration of the secondary antioxidant in the polymercomposition may be in the range up to about 0.4% by weight, and in oneembodiment from about 0.01 to about 0.4% by weight based on the totalweight of the polymer composition, and in one embodiment from about 0.05to about 0.25% by weight. The concentration of the secondary antioxidantin the additive composition that may be used in making the polymercomposition may be in the range up to about 50% by weight, and in oneembodiment from about 3 to about 50% by weight based on the total weightof the additive composition, and in one embodiment from about 10 toabout 40% by weight.

The antistatic agent may comprise one or more of polyetherestearmide,glycerin monostearate, dodecylbenzenesulfonic acid ammonium salt,dodecylbenzesulfonic acid phosphonium salt, maleic anhydridemonoglyceride, maleic anhydride diglyceride, carbon, graphite and/or ametal powder. The concentration of the antistatic agent in the polymercomposition may be in the range from about 0.02 to about 1% by weightbased on the total weight of the polymer composition, and in oneembodiment from about 0.05 to about 0.5% by weight. The concentration ofthe antistatic agent in the additive composition that may be used inmaking the polymer composition may be in the range from about 0.05 toabout 20% by weight based on the total weight of the additivecomposition, and in one embodiment from about 1 to about 10% by weight.

The heat stabilizer may comprise one or more of phosphorous acid,phosphoric acid, esters of these, and/or condensates of these. Examplesof these may include triphenyl phosphite, tris(nonylphenyl)phosphite,tridecyl phosphite, trioctyl phosphite, trioctadecyl phosphite,didecylmonophenyl phosphite, dioctylmonophenyl phosphite,diisopropylmonophenyl phosphite, monobutyldiphenyl phosphite,monodecyldiphenyl phosphite, monooctyldiphenyl phosphite,bis(2,6-di-tert-butyl-4-methylphenyl)pentaerythritol diphosphite,2,2-methylenebis(4,6-di-tert-butylphenyl)octyl phosphite,bis(nonylphenyl)pentaerythritol diphosphite,bis(2,4-di-tert-butylphenyl)pentaerythritol diphosphite,distearylpentaerythritol diphosphite, tributyl phosphate, triethylphosphate, trimethyl phosphate, triphenyl phosphate,diphenylmonoorthoxenyl phosphate, dibutyl phosphate, dioctyl phosphate,diisopropyl phosphate and/or triphosphoric acid. These compounds may beused alone or in combination of two or more. The concentration of theheat stabilizer in the polymer composition may be in the range up toabout 0.5% by weight based on the total weight of the polymercomposition, and in one embodiment from about 0.001 to about 0.5% byweight. The concentration of the heat stabilizer in the additivecomposition that may be used in making the polymer composition may be inthe range up to about 30% by weight based on the total weight of theadditive composition, and in one embodiment from about 3 to about 30% byweight.

The polymer composition may further comprise one or more meltprocessable glass reinforcing resins or materials. The melt processableglass reinforcing resin may comprise at least one phosphate glass. Themelt processable glass reinforcing resin may have a Tg in the range fromabout 220° C. to about 400° C. The melt processable glass reinforcingresin may be present in the polymer composition at a concentration inthe range up to about 90% by weight based on the weight of the polymercomposition, and in one embodiment from about 0.25 to about 90% byweight, and in one embodiment from about 10 to about 50% by weight. Themelt processable glass reinforcing resin may be present in the polymercomposition at a concentration in the range up to about 40% by volumebased on the volume of the polymer composition, and in one embodimentfrom about 0.1 to about 40% by volume, and in one embodiment from about4.5 to about 25% by volume. Without being bound to any particulartheory, the melt processable glass reinforcing resin may provide thepolymer composition with a higher Tg than the Tg of the polymercomposition without the glass reinforcing resin. The melt processableglass reinforcing resin may increase the temperature resistance,stiffness and/or modulus of the polymer composition. The glassreinforcing resin may reduce the shrinkage of the polymer compositionupon cooling in the mold. The glass reinforcing resin may make themolded articles formed from the polymer composition more abrasionresistant. A suitable melt processable glass reinforcing resin is908YRL, which is a phosphate glass available from Corning. This materialmay have a Tg of about 309° C. and a refractive index of about1.55-1.57. Other phosphate glasses that may be useful are described inU.S. Pat. No. 6,667,258 B2 and U.S. Pat. No. 5,153,151, which areincorporated herein by reference for their disclosures of phosphateglasses. While it may be desirable to match, as closely as possible, therefractive indexes of the polymer and the phosphate glass, it may alsobe desirable to use a phosphate glass having a higher refractive indexthan that of the polymer composition in order to increase the overallrefractive index of the polymer composition.

The glass reinforcing resin may be silane treated to enhance dispersionof the glass reinforcing resin into the polymer and to optionally couplethe glass reinforcing resin to the polymer resin system. Examples ofsilanes that may be used may include Dynasylan DAMO and Dynasylan 9165.Blends of Dynasylan DAMO and Dynasylan 9165 may be used. These may bethermally stable at temperatures up to about 370° C. or higher.

The glass reinforcing resin may be surface treated with one or moretitanates, one or more zirconates, or a mixture thereof. The titanatesand zirconates may comprise one or more organometallic complexes oftitanium or zirconium complexed by one or more organic compoundscontaining functional groups attached to a hydrocarbon linkage. Theorganic compounds may contain one or more, and in one embodiment, two ormore functional groups. The functional groups may comprise one or moreof ═O, ═S, —OR, —SR, —NR₂, —NO₂, ═NOR, ═NSR and/or —N═NR, wherein R ishydrogen or a hydrocarbon group (e.g., alkyl or alkenyl) of 1 to about10 carbon atoms. The titanates and zirconates may include alkoxytitanates and coordinate zirconates. These may include the alkoxytitanates available under the tradenames LICA 12 or KR-PRO, andcoordinate zirconates available under the tradenames KZ 55 or KR 55.

The polymer composition may further comprise one or more pigments, dyes,optical brighteners, flame retardants, or a mixture of two or morethereof. The concentration of each of these additional additives in thepolymer composition may be in the range up to about 1% by weight basedon the total weight of the polymer composition, and in one embodimentfrom about 0.01 to about 0.5% by weight. The concentration of each ofthese additional additives in the additive composition that may be usedin making the polymer composition may be in the range up to about 30% byweight based on the total weight of the additive composition, and in oneembodiment from about 1 to about 20% by weight.

The polymer composition may be made by combining the thermoplastic resinwith the additive composition. The melt processable glass reinforcingresin may be initially combined with the thermoplastic resin and/or theadditive composition. The additive composition may comprise thedispersant, inorganic particulates and dye concentrate, as describedabove. The additive composition may further comprise one or moreantioxidants, UV light stabilizers, heat stabilizers, antistatic agents,pigments, additional dyes, optical brighteners, flame retardants, meltprocessable glass reinforcing resins, or a mixture of two or more. Theadditive composition may be present in the polymer composition in anamount of at least about 0.1% by weight of the total weight of thepolymer composition, and in one embodiment from about 0.1 to about 3% byweight, and in one embodiment from about 0.3 to about 2% by weight.

The additive composition may be in the form of a paste or a dry powder.In one embodiment, the additive composition may comprise a homogenous,free-flowing, dry powder. The additive composition may be capable ofacting as an internal lubricant or processing aid by increasing the flowand/or decreasing the shear of the polymer composition. This may allowfor shorter production cycle times for producing molded products suchas, for example, optical lenses, reduce the processing temperature ofthe polymer composition. This may allow for precision molding of detailsto less than about one micron on a molded product such as an opticallens. The additive composition may have excellent dispersion propertiesto allow for homogenous dispersion of inorganic particulates (e.g.,nanoparticles) and/or antioxidants as well as other additives in thepolymer composition or molded articles made therefrom. The additivecomposition may be hydrolytically stable, which may provide for improvedaging of articles molded in humid environments. The additive compositionmay also have a relatively high optical clarity, which contributes toretaining and improving optical clarity and light transmission of moldedarticles made from the polymer composition. Additionally, it may bedesirable that the additive composition has no adverse affect onsecondary operations such as, for example, printing, bonding, and/orcoating molded articles made from polymer compositions containing theadditive composition. The additive composition may be non-yellowing andprovide resistance to yellowing of molded products that are exposed tohigh temperatures and/or high humidity.

The additive composition may be thermally stable up to about 350° C.,and in one embodiment, up to about 400° C. or higher. This allows forprocessing of a thermoplastic resin and the additive composition attemperatures up to about 350° C., and in one embodiment up to about 400°C. This thermal stability may also improve the thermal aging of thepolymer composition and molded articles made therefrom.

In one embodiment, the additive composition may be a homogenous,free-flowing, dry-power additive composition having the formula shown inTable 5.

TABLE 5 % by Weight of Total Additive Material: Composition: (1) Mixtureof saturated and unsaturated fatty esters; 30-99  or (2) mixture oforganic fatty amides with surfactants; or a mixture of (1) or (2) DyeConcentrate/dry powder 0.05-4    Inorganic particulates with averageparticle 0.5-30  size <100 nm/dry powder High molecular weight, lowvolatility primary 0-30 antioxidant High molecular weight, lowvolatility secondary 5-50 antioxidant UV (ultra-violet) Light Stabilizer0-30

Examples of non-limiting embodiments of suitable additive compositionsare shown in Tables 6-8. The additive composition in Table 6 may besuitable for use in making, for example, high temperature, opticallyclear thermoplastic composites for use in applications, such as cameralenses, where the lens is capable of surviving lead free solder reflowprocessing temperatures.

TABLE 6 % by Weight of Total Additive Material: Composition: (1) Mixtureof saturated and unsaturated fatty esters; 82.98 or (2) mixture oforganic fatty amides with surfactants; or a mixture of (1) and (2) DyeConcentrate/dry powder 2.0 Inorganic particulates with average particle0.86 size <100 nm High molecular weight, low volatility primary 14.16antioxidant Total 100

The additive composition in Table 7 may be suitable for use in making,for example, polymer compositions that may be used to make hightemperature, optically clear molded articles that have enhanced thermaloxidative and hydrolytic oxidative resistance. Suitable applications mayinclude camera lenses and LED's, where the lens is capable of survivinglead free solder reflow processing temperatures, is used at highoperating temperatures greater than about 85° C., is simultaneouslysubjected to a relative humidity greater than about 60%, and issubjected to intense transmission of narrow, short wavelength lightbands (for example, 450 nm).

TABLE 7 % by Weight of Total Additive Material: Composition: (1) Mixtureof saturated and unsaturated fatty esters; 52 or (2) mixture of organicfatty amides with surfactants; or a mixture of both (1) and (2) DyeConcentrate/dry powder 2 Inorganic particulates with average particle 6size <100 nm High molecular weight, low volatility primary 8 antioxidantHigh molecular weight, low volatility secondary 32 antioxidant Total 100

The additive composition in Table 8 may be suitable for use in making,for example, polymer compositions that may be used to make hightemperature, optically clear thermoplastic composites that have enhancedthermal oxidative, hydrolytic oxidative resistance, and photolyticoxidative resistance. Suitable applications may include camera lensesand LED's, where the lens is capable of surviving lead free solderreflow processing temperatures, is used at high operating temperaturesgreater than about 85° C., is simultaneously subjected to a relativehumidity greater than about 60%, is subjected to intense transmission ofnarrow, short wavelength light bands (for example, 450 nm), and issubjected to incidental sunlight.

TABLE 8 % by Weight of Total Additive Material: Composition: (1) Mixtureof saturated and unsaturated fatty esters; 50.6 or (2) mixture oforganic fatty amides with surfactants; or a mixture of both (1) and (2)Dye Concentrate/dry powder 2 Inorganic particulates with averageparticle 6 size <100 nm High molecular weight, low volatility primary 6antioxidant High molecular weight, low volatility secondary 27.4antioxidant UV (ultra-violet) Light Stabilizer 8 Total 100

The additive composition that may be used to make the polymercomposition may be thermally stable up to a temperature of about 400° C.or greater. This additive composition may include at least one fattyester, at least one fatty amide, or a mixture thereof, that arethermally stable up to about 400° C. or greater, and a dye concentratethat is thermally stable up to about 400° C. or greater. This additivecomposition may include one or more of blue dye, violet dye, inorganicparticulates, primary antioxidant, secondary antioxidant, and/or UVlight stabilizer, each of which may be thermally stable up to about 400°C. or higher.

In one embodiment for producing an injection moldable, ultra-hightemperature optical thermoplastic with a suitable viscosity forinjection molding at temperatures up to about 400° C., an additivecomposition comprising the following ingredients may be used:

-   -   (a) at least about 40% by weight, of the total weight of the        additive composition of a dispersant, the dispersant        comprising (1) a mixture of saturated and unsaturated fatty        esters; or (2) mixture of organic fatty amides with surfactants;        or a mixture of both (1) and (2)    -   (b) at least about 0.005% by weight of the total weight of the        additive composition of a mixture of high temperature stable        blue and violet organic dyes, which may be in the form of a dye        concentrate comprising (i) at least about 96% by weight of the        total weight of dye concentrate of (1) a mixture of saturated        and unsaturated fatty esters, or (2) a mixture of organic fatty        amides with surfactants, or a mixture of both (1) and (2); (ii)        at least about 0.05% by weight of the total weight of the dye        concentrate composition of a mixture of high temperature stable        blue and violet organic dyes, and (iii) at least about 0.1% by        weight of the total weight of the dye concentrate of high        temperature stable, transparent, inorganic particulates having        an average particle size less than about 100 nanometers, and in        one embodiment less than about 50 nanometers, the inorganic        particulates having an index of refraction of about 1.4-1.8, and        in one embodiment an index of refraction of about 1.52-1.58;    -   (c) up to about 30% by weight, of the total weight of the        additive composition of a primary antioxidant, which may be in        the form of a high molecular weight, low volatility hindered        phenol;    -   (d) at least about 10% by weight of the total weight of the        additive composition of a secondary antioxidant, and in one        embodiment from about 25 to about 40% by weight of the total        weight of the additive composition, the secondary antioxidant        being in the form of a high molecular weight, low volatility        phosphite having a melting temperature greater than about 200°        C.;    -   (e) at least about 0.05% by weight of the total weight of the        additive composition of high temperature stable, transparent,        inorganic particulates having an average particle size less than        about 100 nm, and in one embodiment less than about 50 nm, the        particulates having an index of refraction of about 1.54-1.58;        and    -   (f) at least about 2% by weight of a UV light stabilizer.

The additive composition may be made by (1) mixing the dye concentrate(b) with the dispersant (a), and then (2) mixing, and optionallygrinding, the resultant mixture from (1) with the inorganic particulates(e), and, optionally, with the primary antioxidant (c), secondaryantioxidant (d), and/or UV light stabilizer (f).

In one embodiment for producing an injection moldable, ultra-hightemperature optical thermoplastic with a suitable viscosity forinjection molding at temperatures up to about 400° C., an additivecomposition comprising the following ingredients may be used:

-   -   (a) at least about 40% by weight, of the total weight of the        additive composition, of at least one zirconate;    -   (b) at least about 0.005% by weight of the total weight of the        additive composition of a mixture of high temperature stable        blue and violet organic dyes, which may be in the form of a dye        concentrate comprising (i) at least about 96% by weight of the        total weight of dye concentrate of a zirconate, (ii) at least        about 0.05% by weight of the total weight of the dye concentrate        of a mixture of high temperature stable blue and violet organic        dyes, and (iii) at least about 0.1% by weight of the total        weight of the dye concentrate of high temperature stable,        transparent, inorganic particulates having an average particle        size less than about 100 nanometers, and in one embodiment less        than about 50 nanometers, the inorganic particulates having an        index of refraction of about 1.4-1.8, and in one embodiment an        index of refraction of about 1.52-1.58;    -   (c) up to about 30% by weight, of the total weight of the        additive composition of a primary antioxidant, which may be in        the form of a high molecular weight, low volatility hindered        phenol;    -   (d) at least about 10% by weight of the total weight of the        additive composition of a secondary antioxidant, and in one        embodiment about 25-40% by weight of the total weight of the        additive composition, the secondary antioxidant being in the        form of a high molecular weight, low volatility phosphite having        a melting temperature greater than about 200° C.;    -   (e) at least about 0.05% by weight of the total weight of the        additive composition of high temperature stable, transparent,        inorganic particulates having an average particle size less than        about 100 nm, and in one embodiment less than about 50 nm, the        particulates having an index of refraction of about 1.54-1.58;        and    -   (f) at least about 2% by weight of a UV light stabilizer.

The additive composition may be made by (1) mixing the dye concentrate(b) with the zirconate (a), and then (2) mixing, the resultant mixturefrom (1) with the inorganic particulates (e), and, optionally, with theprimary antioxidant (c), secondary antioxidant (d), and/or UV lightstabilizer (f).

It may be desirable that the additives, when processed with thethermoplastic resin, not yellow or degrade when subjected to processtemperatures of about 300° C. to about 400° C., while providing otheruseful features and benefits to the molded articles, for example,optical lenses. Without being bound to any particular theory, theadditive composition may possess one or more of the characteristics andprovide one or more of the benefits listed in Table 9.

TABLE 9 Features: Benefits: Internal Increases flow, decreases shear ofthe ultra-high lubricant & temperature polymer composition; shortensproduction processing cycle times for producing optical lenses; reducesaid processing temperature of the polymer composition; allows forprecision molding of details on optical lenses to less than one micron.Excellent Allows for homogeneous dispersion of nano-particles &dispersion organic anti-oxidants in the ultra-high temperature, opticalqualities plastic and optical plastic lenses. Hydrolytically Improvesaging of molded plastic lenses in humid stable environments ThermallyThe additives and the polymer composition may be stable processed attemperatures up to about 400° C.; Improves up to thermal aging of thepolymer composition during molding 400° C. and after molding. Theadditive composition may be essentially non-yellowing during moldingoperations. The molded, optical lenses may have good resistance toyellowing when exposed to high temperatures and high humidity. OpticalRetains and improves optical clarity and light transmission Clarity ofthe molded articles, e.g., ultra-high temperature, optical plasticlenses. Secondary Causes no adverse effect on secondary operations suchoperations as printing, bonding, & coating of the molded, opticalplastic lenses.

In one embodiment, the polymer composition may be an ultra-hightemperature, optical thermoplastic comprising a high temperaturethermoplastic resin and an additive composition that is thermally stableup to about 400° C. or higher. An injection moldable, ultra-hightemperature optical polymer material with a suitable viscosity forinjection molding at temperatures up to about 400° C. and which may beused to make a high temperature resistant, optical plastic lens articleshaving one or more characteristics identified in Table 12 may beprovided by:

-   -   (1) Providing an appropriate thermoplastic resin, in the form of        pellets, in an amount of at least about 97% by weight of the        total weight of the polymer composition.    -   (2) Providing at least about 0.2 by weight of the total weight        of the polymer composition of an additive composition such as,        for example, the additive composition disclosed in Table 5.    -   (3) Heating the thermoplastic resin pellets, to at least about        100° C., and in one embodiment to at least about 145° C., and        drying the pellets to a moisture content less than about 0.01%        by weight of the total weight of the pellets.    -   (4) Introducing at least about 0.2% by weight, and in one        embodiment from about 0.5 to about 1.2%, of the total weight of        the thermoplastic resin pellets, of the dry powder additive        composition of Table 5 onto the heated pellets and tumble        blending the additive composition onto the heated pellets,        causing the additive composition to melt onto or surround the        heated pellets and coat the pellets with the additive        composition, and when cooled, resulting in the thermoplastic        resin pellets being substantially uniformly coated with a an        additive composition.

The resulting polymer composition may be further described withreference to Table 10.

TABLE 10 % by Weight of Total Thermoplastic Material: Composition: (1)Mixture of saturated and unsaturated fatty esters; 0.2-1  (2) mixture oforganic fatty amides with surfactants; or (3) zirconates; or a mixtureof (1), (2) and/or (3) Dye Concentrate 0.003-0.08 Inorganic particulateswith average particle 0.0001-1    size <100 nm High molecular weight,low volatility primary   0-0.2 antioxidant High molecular weight, lowvolatility secondary 0.05-0.3 antioxidant UV (ultraviolet light)stabilizer    0-0.15 Polycarbonate resin, APEC ® TP-0277  97.3-99.75

The inventive polymer compositions may be capable of withstandingprocessing temperatures of up to about 400° C., and in one embodimentfrom about 300° C. to about 400° C. These may be suitable for makinghigh temperature optical lens articles having one or more desirablecharacteristics, such as those listed in Table 13. Also, there may bedifferent types of injection molding machines, methods of injectionmolding, and mold designs that may be used to mold both simple andcomplex lens articles using these polymer compositions. Additionally,these polymer compositions may be suitable for making high temperatureresistant films by extrusion methods and solvent casting methods. Thepolymer composition may be useful in making versatile products of hightemperature resistance that may be optically clear using variousinjection molding processes, with varying mold designs, and forproducing plastic optical lens articles with varying designs, varyingapplications, and varying optical an physical properties. Examples ofsuitable, non-limiting, materials for these purposes are disclosed inTable 11 below.

TABLE 11 Material Type & Description: Example/Function/Source: 1.Mixture of saturated and unsaturated INT-40DHT; Axel Plastic ResearchLaboratories, Inc., fatty esters; mixture of fatty acids, Woodside, NY;dry powder; internal lubricant, process esters & gycerides aid,dispersant for inorganic particulates (e.g., nanomaterials) and otheradditive materials; hydrophobic; internal mold release; no adverseeffect on mechanical properties or secondary operations such as surfacecoating of the thermoplastic resin; melts @ about 65° C.; thermallystable to about 400° C. 2. Mixture of organic fatty amides and INT-33UDY; Axel Plastic Research Laboratories, Inc., surfactants Woodside, NY;dry powder; internal lubricant, process aid, mold release agent;dispersant for inorganic particulates (e.g., nanomaterials) and otheradditive materials; hydrophobic; no adverse effect on mechanicalproperties or secondary operations such as surface coatings of thethermoplastic resin; melts @ about 145° C.; thermally stable to about350° C.; or, alternatively, INT-33 UDS; Axel Plastic ResearchLaboratories, Inc., Woodside, NY; dry powder; internal lubricant,process aid, mold release agent; dispersant for inorganic particulates(e.g., nanoparticles) and other additive materials; hydrophobic; noadverse effect on mechanical properties or secondary operations such assurface coatings of the thermoplastic resin; melts @ about 145° C.;thermally stable to about 400° C. 3. Titanates and/or zirconatesTitanates and/or zirconate. Alkoxy titanate such as LICA 12 or KR-PRO,from Kenrich Petrochemicals, Inc., Bayonne, NJ, and/or coordinatezirconates such as KZ 55 or KR 55, from Kenrich (KEN-REACT ReferenceManual, February, 1985, Kenrich Petrochemicals, Inc.), in liquid orpowder form. To create a powder, the liquid titanate or zirconate may beabsorbed or adsorbed onto inorganic particulates (e.g., fumed silica oraluminum oxide), in suitable consistency. The titanates LICA 12 orKR-PRO may be thermally stable up to about 350° C. or higher in apolymer matrix. The zirconates KZ-55 or KR 55 may be thermally stable upto about 400° C. in a polymer matrix. The titanates may be internallubricant, process aid, dispersant and/or coupling agent for inorganicparticulates (e.g., nanoparticles) and other additive materials. Thetitanates and/or zirconates may be hydrophobic. 4. Dye Concentrate/drypowder HTLT Dye Concentrate; Suncolor Corporation; melts @ 125° C.;thermally stable to over 400° C.; provides consistent, uniform colorquality correcting yellow color formation in the host thermoplasticresin; optically clarifying the thermoplastic resin. 4a. Hightemperature stable blue Amplast Blue R3 or Amplast Blue HB; ColorChemdye/dry powder International Corp., Atlanta, GA, insoluble blue dye;melts @ 170° C.; thermally stable to 400° C. particularly when combinedwith a mixture of saturated and unsaturated fatty esters or amides/drypowder and high temperature resistant, inorganic particulates (e.g.,nanomaterials). 4b. High temperature stable violet Amplast Violet BV orAmplast Violet PK; ColorChem dye/dry powder International Corp.,Atlanta, GA, insoluble violet dye; melts @ 170° C.; thermally stable to400° C. particularly when combined with a mixture of saturated andunsaturated fatty esters or amides/dry powder and high temperatureresistant, inorganic particulates (e.g., nanomaterials). 5. Inorganicparticulates with average Aluminum Oxide C or AEROXIDE Alu US; Degussaparticle size <100 nm/dry powder Corporation, Piscataway, NJ; averageparticle size less than about 100 nm, and in one embodiment less thanabout 50 nm; dry powder dispersant and suspension aid; flow aid forthermoplastics; high temperature resistance in excess of 1000° C.; aidsin the uniform dispersion of visible light. 6. High molecular weight,low volatility Cyanox 1790; Cytec Industries, West Paterson, NJ; primaryantioxidant primary hindered phenolic stabilizer (1,3,5-Tris(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl) s-triazine-2,4,6- (1H,3H,5H)-trione);melts @ 160° C.; thermally stable to 400° C. when combined with amixture of saturated and unsaturated fatty esters or amides/dry powderand high temperature resistant, inorganic particulates (e.g.,nanomaterials); reduces or eliminates yellowing of the thermoplasticresin during high temperature processing. 7. High molecular weight, lowvolatility Doverphos S-9228PC; Dover Chemical Corporation, secondaryantioxidant Dover, OH; solid phosphite antioxidant (Bis (2,4-dicumylphenyl) pentaerythrithol diphosphite); thermally stable to 400°C. when combined with a mixture of saturated and unsaturated fattyesters or amides/dry powder and high temperature resistant, inorganicparticulates (e.g., nanomaterials); reduces yellowing of thethermoplastic resin during high temperature processing; melts @ 220-233°C.; provides hydrolytic and thermal stability to the thermoplastic resinand other thermoplastic materials in the additive composition duringprocessing of the thermoplastic resin and provides long term hydrolytic,photolytic, and thermal stability to the molded articles. 8. UV(ultra-violet) Light Stabilizer Hostavin B-CAP; Clariant Corporation,Charlotte, NC; solid Benzylidene Malonate UV Absorber (Tetraethyl 2,2′(1,4-Phenylenedimethylidyne)Bis Malonate); thermally stable to 400° C.,for short temperature cycles when combined with thermogravically stablemixture of saturated and unsaturated fatty esters, fatty acids, fattyamides, and high temperature resistant, inorganic nanomaterials; melts @137-140° C.; provides hydrolytic and thermal stability to thethermoplastic resin and other thermoplastic materials in the additivecomposition during processing of the polymer composition and provideslong term hydrolytic, photolytic, and thermal stability to the moldedarticles. 9. Polycarbonate resin APEC ® TP 0277 or Apec 9399; BayerMaterial Science LLC, Pittsburgh, PA; transparent, high temperaturepolycarbonate made from Bisphenol A, and/or Bisphenol M, and BisphenolTMC, having a Tg of about 225° C. or higher. 10. Biphenol 4,4′ BIPHENOL,Schenectady International, Schenectady, NY 12301; having a melttemperature greater than 200° C.; as an additive to moderate or increasethe refractive index of the thermoplastic resin (e.g., polycarbonate).The biphenol may be used alone or with a compatible catalyst to increasethe Tg of the thermoplastic resin. The biphenol may improve the UV lightand short visible light resistance of the thermoplastic resin. 11. Otherinorganic particulates Silicon dioxide, silicon, cerium oxide, titaniumdioxide, zirconium oxide, and mixtures thereof; mixtures of one or moreof the foregoing with aluminum oxide; either as a dry powder or in asolvent suspension (e.g., suspension in toluene); used as a reinforcingagent, dispersing agent, and/or an agent to increase the refractiveindex and to increase the temperature resistance of the polymercomposition. These may be available from Degussa Corporation,Piscataway, NJ and Melorium Technologies, Inc., Rochester, NY. 12. Meltprocessable glass resin Phosphate glass which may provide the polymercomposition with a higher Tg than the Tg of the polymer compositionwithout the phosphate glass and may increase the the temperatureresistance, stiffness and modulus of the polymer composition whilereducing the shrinkage of the polymer composition upon cooling in themold and making the molded polymer composition more abrasion resistant.A suitable phosphate glass may be 908YRL, having a Tg of about 309° anda refractive index of about 1.55-1.57, which may be available fromCorning. Other suitable phosphate glass compositions are described inU.S. Pat. No. 6,667,258 B2 and U.S. Pat. No. 5,153,151. While it isdesirable to match, as closely as possible, the refractive indexes ofthe polymer and the phosphate glass, it may also be desirable to use aphosphate glass having a higher refractive index than the polymercomposition in order to increase the overall refractive index of thepolymer composition. 13. Silanes, surface treatments and Silane surfacetreatments such as Dynasylan OCTEO coupling agents (octyltriethoxsilane)and surface treatments and fuctional coupling agents such as Dynasil9165 (phenyltrimethoxysilane), Dynasil DAMO (N-2-Aminoethyl-3-aminopropyltrimethoxysilane), or mixtures thereof,available from Degussa Corporation, Parsipany, NJ, having hightemperature stability greater than about 350° C., for treating inorganicparticulates and melt processable glass resin to improve dispersion intopolymer resins, improve mixing, improve mechanical strength, promotehydrophobicity, and decrease water- vapor transmission. 14. Otherinternal dispersants, hydrocarbon agents, such as natural and syntheticlubricants, and mold release agents, paraffins, polyethylene waxes,fluorocarbons, etc., and materials fatty acid agents, such as stearicacid, hydroxystearic acid, other higher fatty acids, hydroxy fattyacids, etc., fatty amide agents, such as stearamide,ethylenebisstearamide, other alkylene bis fatty amides, etc., alcoholagents, such as stearyl alcohol, cetyl alcohol, other fatty alcohols,polyhydric alcohols, polyglycols, polyglycerols, etc. fatty acid esteragents, such as butyl stearate, pentaerythritol tetrastearate, otherfatty acid esters of lower alcohols, fatty acid esters of polyhydric andmonohydric alcohols, fatty acid esters of polyglycols, etc., andsilicone mold release agents, such as silicone oils, etc., these agentsbeing thermally stable to about 350° C., and in one embodimentpreferably up to about 400° C.; pigments, dyes, optical brighteners,flame retardants, and conductive polymers.

Examples of suitable high temperature polymer compositions in accordancewith the disclosed invention may include the compositions listed inTable 12.

TABLE 12 Additive/% by Weight of Total Thermoplastic Composition:Additive Composition from Table 6, 7 or 8 Material Table 6 Table 7 Table8 1. Additive Composition 0.35 0.60 0.65 (wt %) 2. Polycarbonate resin,99.65 99.40 96.35 APEC ® TP-0277

The polymer composition may be made by providing the thermoplastic resinmaterial in pellet form, heating the thermoplastic resin pellets to asuitable temperature, e.g., at least about 70° C., and in one embodimentin the range from about 70° C. to about 155° C., and in one embodimentfrom about 100° C. to about 135° C., and in one embodiment from about135° C. to about 155° C., and mixing a desirable concentration of theadditive composition with the heated pellets. The pellets may have anydesirable shape including spheres, cubes, cylinders, rods, irregularshapes, and the like. The pellets may have an average particle size inthe range from about 1 micron to about 10,000 microns, and in oneembodiment from about 500 to about 1000 microns. Without being bound toany particular theory, upon mixing with the heated pellets, the additivecomposition is believed to melt onto the surface of the heated pelletsand coat the pellets. In one embodiment, the pellets may besubstantially uniformly coated with the additive composition.

The polymer composition may have a Tg of at least about 220° C., and inone embodiment at least about 230° C., and in one embodiment at leastabout 240° C., and in one embodiment at least about 250° C., and in oneembodiment at least about 260° C., and in one embodiment at least about270° C., and in one embodiment at least about 275° C., and in oneembodiment at least about 280° C.

For optical grade thermoplastics which are to be used in lead freesolder reflow applications, it may be desirable that the molded plasticmaterials have a Tg, measured by DMTA (with a 4° C./min. temperaturerange), higher than about 250° C. For most lens applications, the moldedoptical grade thermoplastic may have visible light transmissionproperties, in the visible light range of 400-1000 nm, of at least about85% after surface reflective losses. In addition, these optical gradethermoplastic lens parts may have other important properties. These mayinclude high optical clarity, very low color, very low haze, photolyticstability, hydrolytic stability, and thermal stability for operationaluse in environments from about −20° C. to about 85° C., inclusive ofenvironments with a relative humidity greater than about 80%. In manyLED lighting applications, the polymer composition may have an operatingtemperature capability in excess of about 100° C., and, in other cases,in excess of about 150° C. In many cases, the molded material may have aclean surface on which optical coatings can be attached and bonded.Table 13 provides a summary of the optical, mechanical, and materialproperties that may be achieved using the inventive polymer compositionfor making injection molded plastic lenses.

TABLE 13 Water-WhiteClarity/ Low Haze (0.5); Low Color (Y.I./0.5);CleanOptical Surfaces/ High Visible Light Transmission 90%) InjectionMoldable Superior Impact Resistance High Index of Refraction (1.555/HighLight Output) High Visible Light Transmission Surface Treatable: (ARCoatings/Max. Illumination) Excellent Thermal Oxidative High Tg (>250°C./DMTA 2° C./ Stability min. ramp) Excellent Hydrolytic OxidationExcellent Photolytic Oxidative Stability Stability (450 nm)

The optical and/or physical properties of the polymer composition may beunsuitable for various applications, and, therefore, it may beadvantageous to upgrade and customize the polymer composition bycompounding before their use to satisfy the requirements of the desiredapplication. Conventional compounding of a polymer composition at highmelt temperatures, particularly higher than about 300° C., may result inan additional heat history that may be disadvantageous. At theseprocessing temperatures, a thermoplastic resin such as polycarbonate maydegrade. Degradation of the thermoplastic resin and certain additivematerials may manifest itself in discoloration, e.g., yellowing, whichmay reduce its light transmission in the visible part of the lightspectrum making the molded article less suitable or unsuitable for useas a lens. This problem may be intensified when organic additives arepresent and the processing temperatures ranges from about 300 to about400° C. as the organic materials may volatilize and cause furtheryellowing and black specs to form.

While optical thermoplastic compositions in accordance with theinvention may be processed with conventional compounding methods, in oneembodiment, an optical device may be manufactured in a continuousinjection molding process leading directly from the raw material to themolded article. The additive composition, polymer composition, andmethods for making the same, as described herein, may provide smooth,dry, additive coated thermoplastic pellets, which may be injectionmoldable without compounding, and the molded article, e.g., opticallens, may be processed directly from the raw materials to form the finalmolded article, e.g., optical lens. Using the inventive additivecompositions and polymer compositions, and employing the methods tomanufacture the coated thermoplastic pellets, a plastic lens may beinjection molded having optical properties which are superior to theoptical properties of the thermoplastic resin used in the polymercomposition. The manufacturing of the thermoplastic pellets may be costeffective and may be accomplished using existing drying and tumblingequipment. The method for manufacturing the coated pellets, as describedherein, may be particularly useful in making camera and LED lensarticles that are extremely small, weighing only, in some cases, 0.25grams (the approximate weight of one or two pellets). By coating pelletssubstantially uniformly, each pellet may contain about 100% by weight ofthe entire polymer composition, ensuring that each lens part made mayalso comprise about 100% by weight of the polymer composition. Whenincorporating more than about 2% by weight of inorganic particulatesand/or melt processable glass reinforcing resins into the polymercomposition, it may be useful to first compound the inorganicparticulates and/or melt processable glass reinforcing resins into thepolymer composition using conventional compounding methods and up toabout 0.3% by weight of each of a high temperature stable dispersingagent and/or primary antioxidant to form the pellets. The pellets maythen be coated with the additive composition as described above,followed by injection molding and/or extruding.

Molded articles, for example, those having a thickness of about 1 mm,made from the inventive polymer composition may have an index ofrefraction of about 1.55, and in one embodiment about 1.56. These moldedarticles may have a luminous transmittance of at least about 85% of themaximum theoretical value of the luminous transmittance, and in oneembodiment at least about 88%. The molded articles may have of haze ofless than about 3, and in one embodiment less than about 1. They mayhave a yellowness index of less than about 3, and in one embodiment lessthan about 1. The molded articles may have a visible light transmissionof at least about 85% after surface reflective losses, and in oneembodiment at least about 88%.

The inventive polymer composition may provide numerous advantages overprior art materials, including one of more of the following. The polymercompositions, when molded, may have excellent optical properties. Lensesmade with the polymer compositions may have a high index of refraction,which may be useful for making camera lenses and LED lens with highillumination capability. The camera lenses may include high temperaturelight transmissible thermoplastic (HTLT) cellular camera lenses and HTLTLED lenses. The camera lenses may be used in camera modules for use inmaking cameras, for example, mobile phone cameras. Lenses made with thepolymer compositions may have a high glass transition temperature andmay be used in solder reflow applications, particularly lead free solderreflow applications which may have high operating temperatures. Thepolymer compositions may have a viscosity lower than the basethermoplastic resin so that conventional plastic processing techniquesmay be used. The polymer compositions may be molded at temperatures inthe range from about 300° C. to about 400° C. without compromisingoptical, mechanical and/or other physical properties of the moldedarticles, e.g., molded lenses. The polymer compositions may be injectedinto molds having temperatures as high as about 235° C. without stickingand without the use of external mold release agents. This may includeprocesses where the resultant molded article, such as a molded lenspart, may be annealed or stress relieved in the hot molds as a normalpart of the molding process. The polymer compositions, when molded, maybe effectively annealed or stressed relieved with conventional annealingmethods, resulting in improved or optimized mechanical and thermalproperties. The polymer compositions, when molded, may have superiorthermal oxidative, hydrolytic oxidative, and/or photolytic oxidativeresistance properties and remain stable and clear in a wide variety ofenvironmental conditions suitable for applications such as LED's andautomotive headlights. The polymer compositions may be used toaccurately mold extremely small lens parts having details as fine asmicron and sub-micron in size. The lenses produced from the polymercompositions may be surface treated with a wide variety of organicand/or metal oxide coatings, including anti-reflective coatings. Theunderside of the lenses may be filled and bonded with adhesives and softsilicone encapsulants for LED and other semiconductor and electronicapplications.

The polymer composition, and the methods for making the same, may not belimited to use in high temperature, optical thermoplastic composites.The polymer composition may be used alone or in combination with otheradditives to make high temperature pigment filled, mineral filled,and/or nanomaterial filled composites, including high index ofrefraction, optical nanomaterial thermoplastic composites, using a hightemperature thermoplastic resin in accordance with the disclosedinvention or other thermoplastic resins, e.g., polycarbonate andpolysulfone resins, encompassing many of the features and benefits ofthe disclosed polymer compositions and molded articles made from thesame. The polymer composition may also be used to make opticalthermoplastic composite materials using other thermoplastic resins,e.g., polycarbonate and polysulfone resins, having lower temperatureresistant properties, yet resulting in thermoplastic composite materialsencompassing many of the same features and benefits of the disclosedhigh temperature thermoplastic composite materials.

The invention may be further understood with reference to the followingexamples. The examples are provided for the purpose of furtherillustrating various aspects of the invention and are not intended tolimit the invention in any manner.

Example 1

A dye concentrate is prepared by mixing and grinding the materials shownin the following Table 14:

TABLE 14 % by Weight of Total Dye Con- Material: centrate Formula:Mixture of saturated and unsaturated 99.4 fatty esters; INT-40DHT Hightemperature stable blue dye/dry powder; 0.2 Amplast Blue R3 Dye Hightemperature stable violet dye/dry powder; 0.2 Amplast Violet BV DyeInorganic particulates with average particle 0.2 size <100 nm; AluminiumOxide C Total 100

An additive composition is prepared by mixing and grinding the foregoingdye concentrate and the materials listed in the following Table 15:

TABLE 15 % by Weight of Total Additive Material: Composition: (1)Mixture of saturated and unsaturated 52.0 fatty esters; INT-40 DHT DyeConcentrate; 1.8 Dye Concentrate Formula from Table 14 Inorganicparticulates with average particle 6 size <100 nm; Aluminium Oxide CHigh molecular weight, low volatility 4 primary antioxidant; Cyanox 1790High molecular weight, low volatility 28.2 secondary antioxidant;Doverphos S-9228PC UV (ultra-violet) Light Stabilizer; 8 Hostavin B-CAPTotal 100

The polymer composition shown in Table 16 is prepared using APEC®TP-0277 polycarbonate resin pellets and the additive composition shownin Table 15. The resin pellets are dried at 135° C. in a vacuum oven for4 hours or until the moisture content is less than 0.01% by weight. Theresin pellets are heated to 135° C., and the additive composition isadded to the resin pellets at a weight ratio of 0.6:99.4 in a tumbleblender. The resin pellets and additive composition are tumble blendedfor 5 minutes or until the additive composition melts onto and coats theresin pellets. The coated resin pellets are cooled at room temperatureto a smooth, dry condition.

TABLE 16 % by Weight of Total Thermoplastic Material: Composition:Mixture of saturated and unsaturated 0.312 fatty esters; INT 40 DHT DyeConcentrate; Example 1 above 0.0108 Inorganic particulates with average0.036 particle size <100 nm; Aluminium Oxide C High molecular weight,low volatility 0.024 primary antioxidant; Cyanox 1790 High molecularweight, low volatility 0.1692 secondary antioxidant; Doverphos S-9228PCUV (ultraviolet light) stabilizer; 0.048 Hostavin B-CAP Polycarbonateresin,; 99.4 APEC ® TP-0277 (Tg 235° C.) Total 100.0

An injection molded, polymeric lens article is made using the coatedresin pellets described above. The coated pellets are heated at 125° C.to provide for a moisture level content of less than 0.01% by weight. Ahopper on the injection molding machine is heated to about 80° C. Anitrogen blanket over the hopper may be employed.

The coated resin pellets are injection molded with a screw injectionmachine. The barrel capacity is sufficient to provide for a shot size ofthe pellets between 50 and 75% of capacity to minimize residence time inthe barrel. The stock temperature is in the range from 320° C. to 380°C. Mold temperatures of 150° C. to 225° C. are used. The molding processconditions are as follows:

Injection Molding Processing Conditions

-   -   Nozzle 350-380° C.    -   Front 345-360° C.    -   Middle 340-350° C.    -   Rear 320-344° C.

The molded article has the following optical properties:

Index of refraction/589.93 nm/1.2 mm thickness/ASTM D-542

1.5555

Actual light transmittance (1.2 mm thickness), 585 nm, %/ASTM D 1746

89.3

Luminous transmittance, max. theoretical value, %/VASE ellipsometer,assuming polished, parallel sides of the tests specimen, so that thetransmission is determined directly from the index of refraction.

400 nm

90.1

700 nm

91.0

1000 nm

91.2

Abbe Number/M-200 Ellipsometer, RetMeas software

33.5

Haze, 1.2 mm thickness/ASTM D 1003

<0.7

Yellowness Index/11.2 mm thickness/ASTM E313

<0.7

Refractive Index Vs. Wavelength/M-200 Ellipsometer Cauchy DispersionEquations

Wavelength (nm) 410.47 435.8 480.39 589.93 643.85 Refractive 1.58441.5776 1.5685 1.5550 1.5509 Index

Refractive Index @ 589.3 nm Vs. Temperature/M-200 Ellipsometer CauchyDispersion Equations

Temperature (° C. ) −40 −25 0 20 40 60 85 100 Refractive Index 1.55901.5579 1.5565 1.5550 1.5530 1.5510 1.5470 1.5454

Theoretical light transmission and actual light transmission data forthe molded article are shown in FIG. 1. The plot on the right side ofFIG. 1 is for two samples of the same material, each with a thickness of1 mm.

Example 2

The polymeric composition of Example 1 is molded into bars having thedimensions of 1×17×4 mm. The molded bars are tested by DMTA (DynamicMechanical Thermal Analysis) by ramping the temperature to beyond 260°at 2° C. per minute with a one herz load, and determining Tg. This testindicates that the molded bars are suitable to withstand shorttemperature spikes up to 260° C. and higher without deformation. Theresults are shown in FIG. 3.

Example 3

Four polymer compositions identified below as compositions 1-4 andhaving the formulations indicated in Table 17 are injection molded toform LED lenses. The LED lenses are subjected to high temperatureoptical thermoplastic solder reflow studies with the results being shownin Table 18.

TABLE 17 % by Weight of Total Thermoplastic Material: Composition:Mixture of saturated and unsaturated fatty esters; 0.312 INT 40 DHT DyeConcentrate; Example 1 above 0.0108 Inorganic particulates with averageparticle 0.036 size <100 nm; Aluminium Oxide C High molecular weight,low volatility secondary 0.05 antioxidant; Doverphos S-9228PCComposition # 1: 99.5912 Polycarbonate resin; APEC ® DP-9389-TMC blend(Tg 220° C.) Composition # 2: 99.5912 Polycarbonate resin; APEC ®DP-9389-TMC blend (Tg 226° C.) Composition # 3: 99.5912 Polycarbonateresin; APEC ® DP-9389-TMC blend (Tg 231° C.) Composition # 4: 99.5912Polycarbonate resin; APEC ® DP-9389-TMC blend (Tg 235° C.)

TABLE 18 Composition #1 Composition #2 Composition #3 Composition #4Modified Apec Modified Apec Modified Apec Modified Apec 220 Vicat 226Vicat 231 Vicat 235 Vicat (Simulations & Actual Solder ReFlowTemperature Studies) SR = Solder ReFlow A = Annealed R = RapidlyAnnealed S = Slowly Annealed U = Unannealed TEST Part Oven/ Test PolymerExposure Hot Plate Pass/ Temp Exposure Overall No. Composition SRSimulations A U Fail (° C.) Time Shrinkage (%) 1. 1 Fully Exposed Oven Nyes P 225 5 minutes 1.1  2. 1 Fully Exposed Oven Yes/R no P 225 5minutes 1.0  3. 1 Fully Exposed Oven Yes/R no P 225 1 minute 0.87 4. 1In Lead Frame Oven Yes/R no F 240 1 minute N/A 5. 1 In Lead Frame HotPlate Yes/R no F 240 1 minute N/A 6. 1 In Lead Frame Hot Plate Yes/R noP 240 30 seconds 0.85 7. 1 In Lead Frame Oven Yes/R no P 240 30 seconds0.84 8. 1 In Lead Frame Hot Plate Yes/R no F 250 30 seconds N/A 9. 1 InLead Frame Oven Yes/S no F 250 30 seconds N/A 10. 2 In Lead Frame OvenYes/S no P 240 1 minute 0.90 11. 2 In Lead Frame Hot Plate Yes/S no P240 1 minute 0.90 12. 2 In Lead Frame Oven Yes/S no F 250 30 seconds N/A13. 2 In Lead Frame Hot Plate Yes/S no F 250 30 seconds N/A 14. 3 FullyExposed Oven Yes/R no P 240 5 minutes 0.9  15. 3 Fully Exposed OvenYes/R no F 250 5 minutes N/A 16. 3 Fully Exposed Oven Yes/R no P 240 1minute 0.88 17. 3 Fully Exposed Oven Yes/R no F 250 1 minute N/A 18. 3In Lead Frame Hot Plate Yes/R no P 240 1 minute 0.84 19. 3 In Lead FrameHot Plate Yes/R no P 250 30 seconds 0.81 20. 3 In Lead Frame Hot PlateYes/R no P 250 1 minute 0.84 21. 3 In Lead Frame Oven Yes/S no P 250 30seconds 0.60 22. 3 In Lead Frame Oven Yes/S no P 250 1 minute 0.62 23. 3In Lead Frame Oven Yes/S no F 250 5 minutes N/A 24. 3 In Lead Frame OvenYes/S no F 260 30 seconds N/A 25. 3 In Lead Frame Hot Plate Yes/S no F260 30 seconds N/A 26. 4 Fully Exposed Oven no yes P 240 5 minutes 0.8627. 4 Fully Exposed Oven no yes P 250 5 minutes 0.90 28. 4 Fully ExposedOven no yes P 260 1 minute 0.89 29. 4 In Lead Frame Hot Plate Yes/R no P250 1 minute 0.88 30. 4 In Lead Frame Hot Plate Yes/R no P 260 1 minute0.89 31. 4 In Lead Frame Hot Plate Yes/R no P 265 30 seconds 0.90 32. 4In Lead Frame Oven Yes/R no P 250 1 minute 0.84 33. 4 In Lead Frame OvenYes/S no P 260 1 minute 0.60 34. 4 In Lead Frame Hot Plate Yes/S no P260 30 seconds 0.59 Test Polymer Solder ReFlow SR OVEN 30 seconds No.Composition (Actual) Tests (3 cycles) (per cycle) 35. 2 In Lead Frame SROven Yes/S no P 225 30 seconds 0.70 36. 2 In Lead Frame SR Oven Yes/S noF 240 30 seconds N/A 37. 3 In Lead Frame SR Oven Yes/S no P 240 30seconds N/A 38. 3 In Lead Frame SR Oven Yes/S no P 250 30 seconds 0.7539. 3 In Lead Frame SR Oven No Yes F 250 30 seconds N/A 40. 4 In LeadFrame SR Oven No Yes P 250 30 seconds 0.89 41. 4 In Lead Frame SR OvenNo Yes P 260 30 seconds 0.84 42. 4 In Lead Frame SR Oven Yes/R no P 25030 seconds 0.58 43. 4 In Lead Frame SR Oven Yes/R no P 260 30 seconds0.60 R = Rapidly annealing parts @ 217° C. for 17 minutes. S = Slowlyannealing parts by ramping temperature up over a 30 minute interval,holding at 215° C. for 30 minutes, then cooling down for 30 minutes.

Example 4

Polymeric composition #4 from Example 3 is solution cast with toluenesolvents into a thin film of 1 mil thickness. The thermal stability ofthe film using DSC-TGA is shown in FIG. 2.

Example 5

Photographs showing stress characteristics of unannealed and annealedhigh temperature, optical thermoplastic resin compositions made from thepolymeric composition of Example 1 and molded into LED lenses are shownin FIGS. 4-6. The thermal stress and flow (mold-in) stress of a lenspart produced with a restricted gate is evaluated. The stresses aremeasured by retardance. The flow stress at the gate is measured to beabout 722 nm. The retardance at the thermally stressed areas is verylow, about 23-25 nanometers. The parts are then annealed with an INSTECheater (+/−0.2° C.). The annealing profile consists of warming the partsto 210° C. for 20 minutes and then annealing the parts at 217° C. for 40minutes. Annealing at 217° C. removes all measurable thermal stress.

The un-annealed lens parts shows a stress concentration, of thermal andprimarily flow stresses, at the gate equal to about 722 nm.

After annealing the lens parts at 217° C., the thermal and flow stressat the gate is virtually eliminated, without deformation. The stressadjacent to the gate, along the base of the part, is dramaticallyreduced to about 210 nm, measured by retardance. (Birefringence can becalculated by dividing retardance by the thickness of the section of thepart measured).

A useful annealing profile by convection oven is:

-   -   1. Warm parts to 210° C. for 20 minutes    -   2. Turn up heat to 217° C. and anneal for 40 minutes.    -   3. Cool at 20° C. per minute.

Under IR heat, a useful annealing profile is to:

-   -   1. Warm parts to 210° C. for 20 minutes, or remove from mold at        215-225° C.    -   2. Anneal immediately on a conveyor, under IR heat, for 3-3.5        minutes at 220° C.

While the invention has been described with reference to variousembodiments, it is to be understood that various modifications maybecome apparent to those skilled in the art upon reading thespecification. Therefore, it is to be understood that the inventionincludes all such modifications that may fall within the scope of theappended claims.

The invention claimed is:
 1. An additive composition for use with athermoplastic resin having a glass transition temperature of at least220° C. for making a molded article, comprising: (a) at least onedispersant, the dispersant being thermally stable at a temperature of atleast 350° C.; (b) inorganic particulates having an average particlesize in the range up to 100 nanometers, the inorganic particulates beingthermally stable at a temperature of at least 400° C. and having anindex of refraction in the range from 1.4 to 1.8; and wherein theadditive composition is thermally stable at a temperature of at least400° C.; wherein the inorganic particulates when combined with thethermoplastic resin form a dispersion with a zeta potential of at least+30 mV or more negative than −30 mV; and wherein the molded articleexhibits a luminous light transmission of at least 85% of the maximumtheoretical value of the luminous transmission.
 2. The composition ofclaim 1 wherein the composition further comprises one or more UV lightstabilizers, heat stabilizers, antistatic agents, pigments, dyes,optical brighteners, flame retardants, melt processable glassreinforcing resin, or a mixture of two or more.
 3. A method of making apolymer composition, comprising: heating pellets of the thermoplasticresin at a temperature of at least about 70° C.; and coating the pelletswith the additive composition of claim
 1. 4. The composition of claim 1wherein the composition further comprises at least one bluing agent. 5.The composition of claim 1 wherein the inorganic particulates aresurface treated with one or more silanes or titanates.
 6. The method ofclaim 3 wherein the thermoplastic resin comprises a polycarbonate. 7.The composition of claim 1 wherein the composition further comprises aprimary antioxidant comprising a hindered phenol which is thermallystable at a temperature of at least about 400° C.
 8. The composition ofclaim 1 wherein the composition further comprises a secondaryantioxidant comprising a phosphite which is thermally stable at atemperature of at least about 400° C.
 9. The composition of claim 1wherein the inorganic particulates comprise aluminium oxideparticulates.
 10. The composition of claim 1 wherein the compositionfurther comprises biphenol.
 11. The composition of claim 10 wherein thebiphenol is 4,4′ biphenol.
 12. The composition of claim 1 wherein themolded article has a haze of less than about
 3. 13. The composition ofclaim 1 wherein the molded article has a yellowness index of less thanabout
 3. 14. The composition of claim 1 wherein the inorganicparticulates are silane treated to enhance the dispersion of theinorganic particulates in the thermoplastic resin.
 15. The compositionof claim 1 wherein the inorganic particualtes are surface treated withone or more titanates, one or more zirconates, or a mixture thereof. 16.The composition of claim 1 wherein the dispersant comprises one or morefatty acids, fatty esters, fatty amides, fatty alcohols, silicones,polyalkylene glycols, or a mixture of two or more thereof.
 17. Thecomposition of claim 1 wherein the dispersant comprises one or moretitanates, one or more zirconates, or a mixture thereof.